g)

Cut the removed intake manifold gaskets to
avoid confusion with new part and or
reinstallation on the vehicle.
13

16. INSPECT PCV VALVE (VENTILATION VALVE)
a) Confirm that the PCV valve is installed to the
cylinder head.
b) Check the condition of O-ring of the PCV valve.

NOTE: If the condition of O-ring is abnormal (crushed
or deformed), replace the PCV valve.
NOTE: It is possible for the PCV valve to be
unintentionally removed during intake manifold
removal:
1) Remove the PCV valve from the intake
manifold.
2) Check the condition of O-ring of the PCV
valve.
3) If the condition of O-ring is abnormal (crushed
or deformed), replace the PCV valve.
4) Apply a light coat of engine oil to the O-ring on
the PCV valve.
5) Reinstall the PCV valve to the cylinder head.

17. DISCONNECT WATER INLET WITH
THERMOSTAT CONNECTOR
a) Disconnect the water inlet thermostat connector.

18. SEPARATE WIRE HARNESS CLAMP BRACKET
(NO. 6 ENGINE WIRE)
a) Using a thin flat-blade screwdriver with its tip
wrapped with protective tape, disengage the tab
and disconnect the connector by moving the
locking tab to the right.

14

b)

Using an 8 mm socket wrench, remove the 2
bolts and wire harness clamp bracket with engine
wire from the No. 1 ventilation case.

19. DISCONNECT NO. 6 ENGINE WIRE AND
SENSOR WIRE
a) Disengage the 3 wire harness clamps and
disconnect the No. 6 engine wire and sensor
wire.

20. REMOVE NO. 1 VENTILATION CASE
a) Prior to removal of the ventilation case, mark the
part with an X or similar mark to indicate this is
the old ventilation case.
b) Remove the 4 bolts and the ventilation case from
the side of the cylinder block.

c)

Disengage the clamp and disconnect the sensor
wire from the ventilation case.

d)

Remove the 3 oil separator gaskets from the No.
1 ventilation case.

NOTE: It is possible for the oil separator gaskets to
fall off the ventilation case during removal. Ensure all
3 gaskets are located and removed from the engine
bay area.
e)

f)

Cut the removed oil separator gaskets to avoid
confusion with new part and or reinstallation on
the vehicle.
Store the removed ventilation case in a container
for removed components to prevent
reinstallation.
15

VIII. INSTALL NEW NO. 1 VENTIALATION CASE
1. INSTALL NEW NO. 1 VENTILATION CASE
a) Install 3 new oil separator gaskets to the new No.
1 ventilation case.

b)

Engage the clamp to reconnect the sensor wire
to the ventilation case.

c)

Temporarily install the new ventilation case to the
cylinder block sub-assembly with the 4 bolts.

Do NOT allow the sensor wire to be
caught between the ventilation case
and the cylinder block. If the wire is
caught between the ventilation case
and engine block, damage may
occur to the wire.
Use a mirror to confirm that the oil separator
gasket protrusions are present between the
ventilation case and cylinder block.
e) Check all 3 gasket protrusions.
NOTE: If gasket protrusion is not visible, it is possible
that oil separator gasket fell off during ventilation case
installation.
d)

Do NOT move to next step until
gasket protrusion is visible for all 3
gaskets.
f)

Tighten the 4 ventilation case bolts to the
following torque specification.
Specified torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)

16

2. RECONNECT NO. 6 ENGINE WIRE AND
SENSOR WIRE
a) Re-engage the 3 wire harness clamps to secure
the No. 6 engine and sensor wire harness.

3. REINSTALL WIRE HARNESS CLAMP
BRACKET (NO. 6 ENGINE WIRE)
a) Using an 8 mm socket wrench, reinstall the wire
harness clamp bracket with engine wire to the
No. 1 ventilation case with the 2 bolts.
Specified torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)
b)

Re-engage the claw and reconnect the
connector.
Confirm connection by carefully
pulling connectors in opposite
direction.

4. RECONNECT WATER INLET THERMOSTAT
CONNECTOR
a) Reconnect the water inlet thermostat connector.

5. REINSTALL INTAKE MANIFOLD AND NO. 2
WATER BY-PASS PIPE
a) Install new intake manifold gaskets in the intake
manifold gasket moldings.

17

b)

Apply a light coat of engine oil to the O-ring on
the PCV valve.

c)

Remove the protective tape previously applied
over intake ports of cylinder head.

NOTE: It is possible to damage the fuel pressure
sensor connector while installing the intake manifold.
Do not connect fuel pressure sensor connector until
after intake manifold is in position near cylinder head.
d)

e)

Position the intake manifold so that the fuel
pressure sensor connector can be seen before
fully installing the intake manifold as shown in the
illustration.
Connect the fuel pressure sensor connector.

f)

Without Stud Bolt:
1) Temporarily reinstall the intake manifold to the
cylinder head sub-assembly with the 5 bolts.

g)

With Stud Bolt:
1) Temporarily reinstall the intake manifold to the
cylinder head sub-assembly.
2) Using an E8 "TORX" socket wrench, reinstall
the 2 stud bolts.
Specified torque:
6.5 N*m (66 kgf*cm, 58 in.*lbf)
3)

h)

Temporarily install the 3 bolts and 2 nuts.

ES300h:
1) Using an 8 mm socket wrench, temporarily
reinstall the No. 2 water by-pass pipe to the
intake manifold with the 2 bolts.

18

i)

ES250:
1) Temporarily reinstall the No. 2 water by-pass
pipe to the cylinder block with the bolt (B).
2) Using an 8 mm socket wrench, temporarily
reinstall the No. 2 water by-pass pipe to the
intake manifold with the 2 bolts (A).

j)

Without Stud Bolt:
1) Tighten the 5 bolts in the order shown in the
illustration.
Specified torque:
24 N*m (245 kgf*cm, 18 ft.*lbf)

k)

With Stud Bolt:
1) Tighten the 3 bolts and 2 nuts in the order
shown in the illustration.
Specified torque:
24 N*m (245 kgf*cm, 18 ft.*lbf)

l)

ES300h:
1) Using the 8 mm socket wrench, tighten the 2
bolts.
Specified torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)

m) ES250:
1) Tighten the bolt (B).
Specified torque:
21 N*m (214 kgf*cm, 15 ft.*lbf)
2)

Using the 8 mm socket wrench, tighten the 2
bolts (A).
Specified torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)

6. RECONNECT NO. 5 ENGINE WIRE
a) Re-engage the wire harness clamp to reconnect
the No. 5 engine wire.

19

7. RECONNECT ENGINE WIRE
a) Re-engage the wire harness clamp to reconnect
the engine wire to the intake manifold.
b) Reinstall the bolt.
Specified torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)
c)

Reconnect the 2 connectors.

8. REINSTALL NO. 1 EGR PIPE SUB-ASSEMBLY
a) Install new EGR inlet gasket to the intake
manifold.

b)

Install new EGR valve adapter gasket to the No.
1 EGR pipe.

c)

Using an 8 mm socket wrench, reinstall the No. 1
EGR pipe to the intake manifold and EGR valve
with the 4 bolts.
Specified torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)

9. REINSTALL PURGE VALVE
For ES300h
a) Reinstall the purge valve to the purge bracket
with the bolt.
Specified torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)

20

10. REINSTALL NO. 3 WATER BY-PASS PIPE
a) Using an 8 mm socket wrench, reconnect the No.
3 water by-pass pipe to the intake manifold with
the bolt.
Specified torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)

11. RECONNECT ENGINE WIRE
a) ES300h:
1) Re-engage the 2 wire harness clamps to
reconnect the engine wire.
2) Reinstall the 2 bolts.
Specified torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)
3)
b)

Reconnect the 3 connectors.

ES250:
1) Re-engage the 2 wire harness clamps to
reconnect the engine wire.
2) Reinstall the 2 bolts.
Specified torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)
3)
4)

Reconnect the 3 connectors.
Re-engage the hose clamp to the reconnect
No. 5 water by-pass hose. (Only for CAMRY)

12. REINSTALL FUEL DELIVERY GUARD
a) Reinstall the fuel delivery guard to the engine
mounting bracket RH with the bolt.
Specified torque:
40 N*m (408 kgf*cm, 30 ft.*lbf)

21

13. RECONNECT NO. 2 FUEL VAPOR FEED HOSE
a) Reconnect the No. 2 fuel vapor feed hose to the
intake manifold.

14. INSTALL THROTTLE BODY ASSEMBLY
a) Install new throttle body gasket to the intake
manifold with the protrusion of the throttle body
gasket oriented as shown in the illustration.
NOTE: The shape of throttle body gasket differs
between gasoline vehicles and hybrid vehicles.
b)

Using an 8 mm deep socket wrench, install the
throttle body assembly to the intake manifold with
the 3 bolts.
Specified torque:
10 N*m (102 kgf*cm, 7 ft.*lbf)

c)

Reconnect the throttle body assembly connector.

22

15. REINSTALL FOLLOWING COMPONENTS
• Cool air intake duct seal
• Air cleaner cap with air

cleaner hose

• Inlet air cleaner assembly
• Air cleaner filter element

• No. 1 engine cover sub-

assembly

sub-assembly

16. CONNECT NEGATIVE BATTERY TERMINAL CONNECTION
17. PERFORM SYSTEM INITIALIZATIONS
18. CHECK FOR DTC’S

◄ VERIFY REPAIR QUALITY ►
•
•
•

Confirm that all parts listed in the Components Diagrams have been properly installed on
the vehicle
Start vehicle and confirm that no indicator lights are illuminated
With engine running, confirm no oil leaks are present in engine bay from PCV ventilation
case area.

23

IX.

APPENDIX

A. PARTS DISPOSAL
In accordance with Federal law, please make sure all parts (original parts)
removed from the vehicle are disposed of in a manner in which they will not be reused,
unless requested for parts recovery return.

CAMPAIGN DESIGNATION DECODER

22LC02
19

T

A

01

Year Campaign
is Launched

Vehicle Make

Field Action Category and Phase

Field Action Sequence

19 = 2019
20 = 2020
21 = 2021
22 = 2022
23 = 2023
Etc...

T = Toyota
L = Lexus

A = Safety Recall Remedy
B = Safety Recall Interim
C = Special Service Campaign
D = Limited Service Campaign
E = Customer Support Program
F = Emissions Recall
(May use other characters in unique cases)

01 = 1 st Field Action of the year
02 = 2 nd Field Action of the year
03 = 3 rd Field Action of the year
(The sequence is unique for each Field
Action category)
(May use other characters in unique
cases)

Examples:
19TA01 = Launched in 2019, Toyota, Safety Recall Remedy Phase, 1st Safety Recall Launched in 2019
20TC02 = Launched in 2020, Special Service Campaign, 2nd Special Service Campaign Launched in 2020
21TE05 = Launched in 2021, Customer Support Program, 5th Customer Support Program Launched in 2021

24